Flexible Thinking: Additive Manufacturing of PCBs

“It’s hard to make predictions, especially about the future.” –Yogi Berra

Yogi Berra and several other more scientifically minded individuals (including no less than pioneering physicist Nils Bohr) have been proven right time and again with their simple but astute observations about predicting the future. The future is indeed very difficult to predict, but certain things can be intuited with a modicum of logic and a bit of wild-eyed speculation. Some fellow soldiers and I, serving with the 101st Airborne, “invented” what is now called virtual reality (VR) and/or augmented reality (AR) in Vietnam 50 years ago during some of our less frenetic off-hours. It was based on our steel pot helmets, and it had a curved display that gave a 180° field of view and speakers placed around it that provided 3D sound (we did not, however, envision stereoscopic vision to provide 3D imaging, as I recall).

Of course, we had no way to implement our outrageous ideas because the technologies required to support our collective vision were not available until now. I am willing to assert without proof that there were likely others who may have had a similar and contemporary inspiration. Most certainly, there have been numerous others who have had similar ideas since, as evidenced by the Oculus VR headset, which is now available.

We are seeing increasing interest in technologies that will allow one to make electronic substrates in near real-time using additive processing techniques and 3D printers. It is a true game-changer in product development. The surge in interest in additive manufacturing technologies shown in recent times—as indicated by the significant increase in published articles and press releases—suggests that the electronic interconnection manufacturing industry could be on the verge of a manufacturing renaissance.

To read this entire column, which appeared in the November 2019 issue of Design007 Magazine, click here.

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2020

Flexible Thinking: Additive Manufacturing of PCBs

01-23-2020

We are seeing increasing interest in technologies that will allow one to make electronic substrates in near real-time using additive processing techniques and 3D printers. It is a true game-changer in product development. The surge in interest in additive manufacturing technologies shown in recent times—as indicated by the significant increase in published articles and press releases—suggests that the electronic interconnection manufacturing industry could be on the verge of a manufacturing renaissance.

View Story
Back

2019

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2018

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2017

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2016

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2015

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2014

Flexible Thinking: Standards—An Industrial-strength Glue

10-21-2019

Standards are frequently viewed as cumbersome nuisances and impediments to progress by those pressing for rapid change. The process of writing, getting approval, and promulgating standards can be arduous and frustrating. It has a lot of similarities to the creation and passage of laws in various government bodies in that there are many opinions and interested parties who engage in the process to make sure that it results in a product that does not damage or favor one solution or party over another.

View Story

Flexible Thinking: Making Flexible Circuits Stretchable

09-05-2019

It is my opinion that the initial driving impetus for the development of stretchable circuits was a bit different than normal, meaning that military and aerospace have traditionally driven the development of arcane electronic interconnection technologies as they did with the development of both flexible and rigid-flex circuits. In contrast, it was a consumer-driven market that appears to have been the gate opener in the form of wearable electronics.

View Story

Flexible Thinking: How to Get From Here to There

04-26-2019

To begin any process, you must first know where you are going. This is true for any project or life pursuit, I believe, and I often try to bring it to mind as I start any new project. With respect to developing products that might benefit from flexible circuit technology, this is no less true. Find out why.

View Story

A Few Simple Lessons in Designing Reliable 3D Flex

04-11-2019

We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we're only human. Unfortunately, using only familiar tools limits our ability to come up with optimal or even superior solutions. This article will help you avoid some of the traps conventional wisdom doesn't always give guidance on.

View Story

Flexible Thinking: Ways to Conserve Flex Circuit Material in the Design Process

02-25-2019

In summary, the decisions made by the flex circuit designer when laying out a flex circuit will have an impact that lasts the entire process. By considering how the circuit might fit onto a panel before submitting the design to a manufacturer, it may be possible to save a considerable amount of material and money.

View Story

Flexible Thinking: A Few Simple Lessons in Designing Reliable 3D Flex

02-11-2019

There is an old and familiar adage that goes something like this: “If the only tool in your tool chest is a hammer, you tend to see every problem as a nail.” We all have a tendency to stick close to the familiar and use the tools we know to create solutions to problems confronting us; we’re only human.

View Story
Back

2013

The E.I. Files: The Electronics Industry's Black Swans

07-31-2013

First proposed in 2007, there is a potential electronics industry "black swan" technology quietly being developed and refined. It is one that could greatly and positively impact, at once, the cost, reliability, and environmental friendliness of electronic manufacturing by simply eliminating the soldering process.

View Story

Flex Circuits and Photonics: A Pairing for the Future, and the Here and Now

04-17-2013

Photons are making continuous headway into the world of electronics. One thing that the basic data carriers (electrons, microwaves and photons) have in common is that flexible circuits are being increasingly looked to for help in managing their data transmission function.

View Story
Back

2012

The E.I. Files: The Electronics Industry's Black Swans

07-31-2013

First proposed in 2007, there is a potential electronics industry "black swan" technology quietly being developed and refined. It is one that could greatly and positively impact, at once, the cost, reliability, and environmental friendliness of electronic manufacturing by simply eliminating the soldering process.

View Story

Flex Circuits and Photonics: A Pairing for the Future, and the Here and Now

04-17-2013

Photons are making continuous headway into the world of electronics. One thing that the basic data carriers (electrons, microwaves and photons) have in common is that flexible circuits are being increasingly looked to for help in managing their data transmission function.

View Story
Back

2011

Something Old, Something New: Stretchable Circuits and Elastronics

10-13-2011

The stretching of circuits to alternately increase and decrease the length of a circuit has proven useful for electronic products and assemblies for years. Stretchable circuit technology and elastronics are poised to take on challenges that cannot be easily met by flexible circuit technology alone. Keep them in mind next time you find yourself in need of a little more "spring" in your design. By Joe Fjelstad.

View Story

Stretchable Circuits: The Emergence of "Elastronics"

07-14-2011

The stretchable circuit is an interesting and promising new branch on the flexible circuit tree. The stretching of circuits to alternately increase and decrease the length of a circuit has proven useful for many years. The European Union has funded research in this area through such initiatives as the STELLA project.

View Story
Back

2010

Something Old, Something New: Stretchable Circuits and Elastronics

10-13-2011

The stretching of circuits to alternately increase and decrease the length of a circuit has proven useful for electronic products and assemblies for years. Stretchable circuit technology and elastronics are poised to take on challenges that cannot be easily met by flexible circuit technology alone. Keep them in mind next time you find yourself in need of a little more "spring" in your design. By Joe Fjelstad.

View Story

Stretchable Circuits: The Emergence of "Elastronics"

07-14-2011

The stretchable circuit is an interesting and promising new branch on the flexible circuit tree. The stretching of circuits to alternately increase and decrease the length of a circuit has proven useful for many years. The European Union has funded research in this area through such initiatives as the STELLA project.

View Story
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